U.S. patent application number 10/921699 was filed with the patent office on 2005-04-07 for solid state multi-pole switching device for plug-in switching units.
Invention is credited to Tanis, James.
Application Number | 20050073789 10/921699 |
Document ID | / |
Family ID | 34396176 |
Filed Date | 2005-04-07 |
United States Patent
Application |
20050073789 |
Kind Code |
A1 |
Tanis, James |
April 7, 2005 |
Solid state multi-pole switching device for plug-in switching
units
Abstract
A solid state multi-pole switching device has input terminals
for a plurality (n) of input control circuits, output terminals for
a plurality (m) of output circuits each having an associated
solid-state switch unit for switching a respective external circuit
load, and a field-programmable unit coupled between the n input
control circuits and the m output circuits for selectively
establishing an electrical connection of any input control signal
to any selected output circuit. The device components are carried
on a main circuit board, with the solid state switch units (Triacs)
mounted on plug-in boards selectively installed in an array of
sockets on the main circuit board. The field-programmable unit may
be a simple pin-and-jumper array, or a CPU coupled to an LCD
display and settings control device. Timer controls may be
programmed through the CPU for automatic on/off switching without
the need to manually activate the input control circuits. The
device allows a field installer or user to program the desired
input/output switching connections onsite, with output circuits
being grouped and controlled by input control signals in any
desired combination. The device can be used in a wide range of
multi-circuit switching control applications such as commercial,
industrial or home lighting applications including, but not limited
to, stadium lighting, office space lighting, industrial plant
lighting, school lighting, home interior or exterior lighting, or
store lighting and display.
Inventors: |
Tanis, James; (New York,
NY) |
Correspondence
Address: |
OSTRAGER CHONG FLAHERTY & BROITMAN PC
250 PARK AVENUE, SUITE 825
NEW YORK
NY
10177
US
|
Family ID: |
34396176 |
Appl. No.: |
10/921699 |
Filed: |
August 19, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60498724 |
Aug 28, 2003 |
|
|
|
Current U.S.
Class: |
361/100 |
Current CPC
Class: |
H01H 9/547 20130101;
H01H 2300/04 20130101; H05K 1/14 20130101; H05K 3/222 20130101;
H05K 1/0286 20130101 |
Class at
Publication: |
361/100 |
International
Class: |
H02H 003/00 |
Claims
1. A solid state multi-pole switching device comprising: (a) a
first plurality (n) of input control circuits each configured to
provide an individual input control signal for controlling the
switching of one or more output circuits; (b) a second plurality
(m) of output circuits each having an associated solid-state switch
unit connected to an output terminal (pole) connectable to a
respective external circuit load; (c) a field-programmable unit
coupled between the n input control circuits and the m output
circuits for selectively establishing an electrical connection
connecting any input control signal to one or more solid-state
switch units for any selected one or more of the output circuits,
whereby the n input control circuits can be connected by the
field-programmable unit to any of the m solid state switch units
for the output circuits in any desired combination of groupings
controlled by any selected ones of the input control signals.
2. A solid state multi-pole switching device according to claim 1,
wherein input terminals for the input control circuits, solid-state
switch units, and output terminals (poles) for the output circuits
are all carried on a main circuit board.
3. A solid state multi-pole switching device according to claim 2,
wherein said main circuit board has an array of sockets for
selectively installing the switch units mounted on plug-in circuit
boards therein.
4. A solid state multi-pole switching device according to claim 1,
wherein said field-programmable unit is provided by n pin-jumper
positions for each of the m output circuits, and desired
connections are established by installing jumpers connecting each
selected input control circuit to each selected output circuit.
5. A solid state multi-pole switching device according to claim 1,
wherein said field-programmable unit is provided by a CPU coupled
to a display and a settings control device for establishing desired
electronic connections from each selected input control circuit to
each selected output circuit.
6. A solid state multi-pole switching device according to claim 5,
wherein said CPU has a settings program which provides a menu to
enable the user to set desired connections to the selected output
circuits for any of the input control circuits.
7. A solid state multi-pole switching device according to claim 5,
wherein said settings control device is a settings control knob
that is turned to scroll up/down through numbers and/or menu
options and pushed to set or execute a number or option.
8. A solid state multi-pole switching device according to claim 5,
wherein said CPU includes a timer control program for setting 7-day
calendar controls for each input control circuit for automatic
on/off switching operation of the selected output circuits without
the need to manually activate external input control signals.
9. A solid state mult-pole switching device according to claim 6,
wherein said settings program operates in a mode where said input
control signal of only one of said input control circuits controls
said output terminal (pole) of one of said output circuits.
10. A solid state multi-pole switching device according to claim 6,
wherein said settings program operates in a mode where said input
control signal of more than one of said input control circuits
controls said output terminal (pole) of one of said output
circuits.
11. A solid state multi-pole switching device according to claim 2,
wherein said main circuit board includes timer controls for setting
7-day calendar controls for each input control circuit for
automatic on/off switching operation of the selected output
circuits without the need to manually activate external input
control signals.
12. A solid state multi-pole switching device according to claim 1,
adapted for field installation or onsite operation of multi-circuit
switching control.
13. A solid state multi-pole switching device comprising: (a) a
main circuit board having input terminals for a first plurality (n)
of input control circuits, each configured to provide an individual
input control signal for controlling the switching of one or more
output circuits, and output terminals for a second plurality (m) of
output circuits, each having an associated solid-state switch unit
connected to a respective output terminal (pole) connectable to a
respective external circuit load; and (b) a field-programmable unit
coupled between the input terminals for the n input control
circuits and the output terminals for the m output circuits for
selectively establishing an electrical connection connecting any
input control signal to one or more solid-state switch units for
any selected one or more of the output circuits.
14. A solid state multi-pole switching device according to claim
13, wherein said main circuit board has an array of sockets for
selectively installing the switch units mounted on plug-in circuit
boards therein.
15. A solid state multi-pole switching device according to claim
13, wherein said field-programmable unit is provided by n
pin-jumper positions for each of the m output circuits, and desired
connections are established by installing jumpers connecting each
selected input control circuit to each selected output circuit.
16. A solid state multi-pole switching device according to claim
13, wherein said field-programmable unit is provided by a CPU
coupled to a display and a settings control device for establishing
desired electronic connections from each selected input control
circuit to each selected output circuit.
17. A solid state multi-pole switching device according to claim
16, wherein said CPU has a settings program which provides a menu
to enable the user to set desired connections to the selected
output circuits for any of the input control circuits.
18. A solid state multi-pole switching device according to claim
16, wherein said settings control device is a settings control knob
that is turned to scroll up/down through numbers and/or menu
options and pushed to set or execute a number or option.
19. A solid state multi-pole switching device according to claim
16, wherein said CPU includes a timer control program for setting
7-day calendar controls for each input control circuit for
automatic on/off switching operation of the selected output
circuits without the need to manually activate external input
control signals.
20. A solid state mult-pole switching device according to claim 17,
wherein said settings program operates in a mode where said input
control signal of only one of said input control circuits controls
said output terminal (pole) of one of said output circuits.
21. A solid state multi-pole switching device according to claim
17, wherein said settings program operates in a mode where said
input control signal of more than one of said input control
circuits controls said output terminal (pole) of one of said output
circuits.
22. A solid state multi-pole switching device according to claim
13, wherein said main circuit board includes timer controls for
setting 7-day calendar controls for each input control circuit for
automatic on/off switching operation of the selected output
circuits without the need to manually activate external input
control signals.
23. A solid state multi-pole switching device according to claim
13, wherein said main circuit board includes an on-board power
supply control for supplying power to loads on the switched output
circuits.
24. A solid state multi-pole switching device according to claim
13, adapted for multi-circuit switching control applications.
Description
[0001] This U.S. patent application claims the priority of U.S.
Provisional Application No. 60/498,724 filed on Aug. 28, 2003,
entitled "Solid State Multi-Pole Switching Device With Circuit
Grouping", of the same inventor.
TECHNICAL FIELD
[0002] This invention generally relates to a solid state switching
device, and more particularly, to one which can handle multi-pole
switching circuits.
BACKGROUND OF INVENTION
[0003] Switching devices that employ a mechanical contact to switch
power on/off to a circuit are subject to mechanical failure, wear,
corrosion, current transients, and other problems that can degrade
their performance. For example, U.S. Pat. No. 4,430,579 to D.
Wiktor describes a previous type of "Electrically Operated,
Mechanically Held Electrical Switching Device". The switching
actuator is solenoid operated with an armature movable between two
positions and held in each position by a spring-biased element. It
would be desirable to provide an improved switching device that has
no moving contacts to create unwanted electrical noise or
deteriorate over time, and that can perform on/off switching more
controllably and with faster times.
[0004] Solid state switching devices have been developed which
overcome many of the problems of the mechanical switching devices.
U.S. Pat. 4,801,828 to Ishikawa et al. describes a typical
"Multiphase Solid-State Contactor" which employs a multiphase input
signal to electronically switch three thyristor firing circuits for
controlling the 3-phase power supply to an electric utility
customer. However, this prior type of solid-state switching device
is used to switch connected or dedicated circuits, and cannot
readily be used to switch multiple circuits grouped together in
selected groups and controlled by selectable input control signals.
For example, it would be desirable to have a solid-state switching
device that an installer or user can configure in the field or a
user can configure for onsite operation to enable selected input
control signals to control selected ones of a large array of
commercial, industrial or home lighting circuits, including but not
limited to lighting circuits for stadiums, office spaces,
industrial plants, schools, home interior, exterior, and lawn, or
store lighting and display circuits for daylight, night-time, and
after-hours operation.
SUMMARY OF INVENTION
[0005] In accordance with the present invention, a solid state
multi-pole switching device comprises:
[0006] (a) a first plurality (n) of input control circuits each
configured to provide an individual input control signal for
controlling the switching of one or more output circuits;
[0007] (b) a second plurality (m) of output circuits each having an
associated solid-state switch unit connected to an output terminal
(pole) connectable to a respective external circuit load;
[0008] (c) a field-programmable unit coupled between the n input
control circuits and the m output circuits for selectively
establishing an electrical connection connecting any input control
signal to one or more solid-state switch units for any selected one
or more of the output circuits,
[0009] whereby the n input control circuits can be connected by the
field-programmable unit to any of the m output circuits in any
desired combination of groupings controlled by any selected ones of
the input control signals.
[0010] In a preferred embodiment, input terminals for the input
control circuits, solid-state switch units, and output terminals
(poles) for the output circuits are all carried on a main circuit
board. The output circuits have their output terminals arranged in
an array of a selected maximum number (e.g., m=16), and a
corresponding array of sockets for plug-in switch units (Triacs)
which can be installed as needed on the main board up to the
maximum number. The input control circuits have respective terminal
blocks for installing input contact switches up to a selected
number (e.g., n=4). The input contact switches may be maintained or
momentary contact switches (e.g., a rocker or pushbutton), or may
include motion sensors, photo cells, or remote actuated switches.
The field-programmable unit may be in a simplified form having n
pin jumper positions for each of the m output circuits, and the
desired connections are established by field-installing jumpers on
the main board between each selected input control circuit and each
selected output circuit. Alternatively, the field-programmable unit
may take the more advanced form of a CPU for setting the
input/output connections using an LCD display and settings control
knob to enable a field installer or onsite user to program the
desired connections. Timer controls may be programmed through the
CPU for automatic on/off switching without the need to manually
activate the input control circuits.
[0011] The solid state multi-pole switching device of the present
invention allows an installer or user to program the desired
input/output switching connections in the field or for onsite
operation. The output circuits can be grouped and controlled by
input control signals in any desired combination. The device can
therefore be used in a wide range of multi-circuit switching
control applications such as commercial, industrial or home
lighting, including but not limited to store lighting and display,
stadium lighting, office space lighting, industrial plant lighting
or school lighting. It is made modular so that only the necessary
input control modules and output switch units need to be installed
at any time. The modular components can be individually replaced
without replacing the entire unit, or disturbing other circuits.
After initial installation, more control modules and/or plug-in
switch units can be easily installed and programmed as desired.
[0012] Other objects, features, and advantages of the present
invention will be explained in the following detailed description
of the invention having reference to the appended drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0013] FIG. 1A is a block diagram of input control circuits in a
first embodiment of the present invention, and FIG. 1B shows the
pin jumper arrays used to program the desired input/output
connections to output circuits in the first embodiment.
[0014] FIG. 2 is a plan view of a main circuit board layout for the
first embodiment showing the pin jumper arrays without the other
components installed.
[0015] FIG. 3 is a front elevation view of the circuit board in
FIG. 2 taken along view lines A-A.
[0016] FIG. 4 is a side elevation view of the circuit board in FIG.
2 taken along view lines B-B.
[0017] FIG. 5 is a schematic logic diagram depicting an example of
the first embodiment in a typical scenario of operation.
[0018] FIG. 6 is a block diagram of an overall circuit
configuration for a second embodiment showing a CPU and on-board
LCD display and setting control used to program the desired
input/output connections in the second embodiment.
[0019] FIG. 7 is a plan view of a circuit board layout for the
second embodiment showing the modular socket arrays without the
other components installed.
[0020] FIG. 8 shows a typical installation wiring scenario for an
example of the second embodiment in operation.
[0021] FIGS. 9A-9G illustrates a programming sequence for
programming an input control signal to selected ones of the output
circuits (poles).
[0022] FIG. 10 illustrates a control signal setup menu for the CPU
in the second embodiment for programming of the input control
signals.
[0023] FIG. 11 illustrates a logic diagram for programming the CPU
in the second embodiment for programming of the input control
signals.
DETAILED DESCRIPTION OF INVENTION
[0024] In the following description, certain representative
examples of the solid state multi-pole switching device of the
present invention are described with reference to specific types
and numbers of components. A first embodiment is described having 3
input control circuits, 12 output circuits, and a pin jumper array
for programming the input/output connections, and a second
embodiment is described having 4 input control circuits, 16 output
circuits, and a CPU with LCD display for programming the
input/output connections. However, it should be understood that the
invention is not limited in the type and number of switched
circuits or input control circuits, or manner of implementing a
field-programmable unit for establishing the input/out
connections.
[0025] In FIG. 1A, an overall circuit configuration for the first
embodiment of the invention has a control signal input terminal
strip 10 mounted on a main printed circuit board (PCB) 11 which is
connected by connectors 12 to input control circuits CRTL-A,
CRTL-B, CRTL-C that provide signal traces 15A, 15B, 15C,
respectively, when their switch actuator (such as a pushbutton or
rocker actuator) is closed. The input control signals are sent to
control signal rectifying and regulating circuits 32 which are
mounted on removable PCBs and output as signals 17A, 17B, 17C,
respectively. Control signal rectifying and regulating circuits 32
may contain a full wave rectifier, control transformer, current
limiting resistors and filter capacitors to create the regulated
input control signals 17A, 17B, 17C. The main printed circuit board
11 is constructed with male terminals that plug into female printed
terminals of the removable PCBs. Expansion control signal input
terminals 26 and output terminals 28 are provided in the event it
is desired to add another main PCB in parallel for expansion.
[0026] In FIG. 1B, the regulated control signals 17A, 17B, 17C are
sent on branch wiring lines to a series of selector pins for each
of the array of switch units 34 carried on the main PCB. In this
case, since there are 3 input control signals, there are 3 selector
pins 13A, 13B, 13C that can connect any input control signal 17A,
17B, 17C to each switch unit 34. A connection is established
between any of the pins 13A, 13B, 13C with a pin jumper 14 to the
input terminals of the switch unit 34. Each switch unit 34 is
mounted on a plug-in PCB and consists of a Triac switching circuit
that is controlled by the input control signal provided. Triac
switching circuits are well known in the industry, and are not
described further herein. In this example, up to 12 switch units on
plug-in PCBs can be mounted on the main PCB 11. Output lines from
the 12 switch unit positions are sent to output terminal strip 30
(12 poles, 24 terminal pins) which can be connected by connectors
40 to respective circuits supplying power to loads Z.
[0027] In FIGS. 2, 3, and 4, the layout of the main printed circuit
board 11 of the first embodiment is shown, without the other
components installed, having the input terminal strip 10, expansion
connectors 26 and 28, sockets for the plug-in control signal
rectifying and regulating circuits 32, pin arrays 13A, 13B, 13C and
selected jumpers 14, sockets for the plug-in Triac switch units 34,
output terminal strip 30. Installation and setup of the solid state
multi-pole switching device by an installer in the field or a user
for onsite operation is quite simple. The installer connects the
input lead wires 12 from the desired input control switches to the
control signal input terminal strip 10. The switched output circuit
lead wires 40 are connected to the output terminal strip 30. A
plug-in PCB with Triac switching circuit 34 is installed on the
main PCB 11 for each switched output circuit 40 connected to the
switching device. A pin jumper 14 is placed on the appropriate
selector pins 13A, 13B or 13C of each switching circuit 34,
depending on which input control switch CRTL-A, CRTL-B, CRTL-C is
selected to control which switched output circuit. In the event
additional PCBs 11 are needed to accommodate a larger number of
switched output circuits 40, expansion control signal input
terminals 26 and output terminals 28 are provided. The user simply
connects a ribbon cable jumper between the two PCBs 11 to provide
the regulated control signals 17A, 17B, 17C to the added PCB
without any further field wiring.
[0028] The end result is that, when the user switches on any of the
control switches CRTL-A, CRTL-B, CRTL-C, the jumper-connected
switched output circuits 40 will also switch on (and vice-versa for
off). For example, in FIG. 5, when control signal 15A is on, all
switched output circuits 40 that have selector pins 13A jumped will
be on. Similarly, when control signal 15C is on, all switched
output circuits 40 that have selector pins 13C jumped will be on.
Since the control signal 15B is off, the switched output circuits
40 that have selector pins 13C jumped remain off.
[0029] In the event more switched circuits need to be added after
field installation, additional plug-in PCBs containing a Triac
switching circuit 34 can be plugged into the main PCB 11.
Similarly, if additional control signal lines become necessary,
additional plug-in PCBs 32 containing control signal rectifying and
regulating circuits can be plugged into the main PCB 11.
[0030] Other types of components, methods of construction, and
features may be substituted or used given the principles of
operation of the switching device. Different numbers ("n") of input
control circuits and ("m") of switch units and switched output
circuits may be used. Other types of semiconductor switching
circuits, opto-isolators, switch control devices that operate with
AC or DC input, transistor type output circuits, random crossing
and zero crossing Triac output circuits, various thyristor circuits
including silicon controlled rectifiers (SCRs), silicon controlled
switches (SCS), 4-layer diodes, and Diacs may be used. Other
alternatives to the pin and jumper arrangement include mechanical
switches, solid state switching circuits or screwed down contact
jumpers, and a computer CPU-controlled embodiment is described
below. Alternatives to the described main and plug-in PCBs
described including reversing the male/female arrangement of the
terminals, or using quick connect type terminals, screwed down
contacts and supports, twist lock connectors, headers, pins,
sockets and receptacles, terminal blocks and wire. An alternative
to the modular component design is to put all the device components
on a single printed circuit board. Other features that can be added
to the device include a front panel display indicating device
conditions, pilot lights, LEDs, LCD display, LCD or TFT screen,
auxiliary contacts for each controlled circuit, circuit board
rearrangement for space saving or cost effectiveness, internal
control power source, timer circuits for automatic operation
without external control signals, local circuit control, override
switches, etc.
[0031] In FIG. 6, an alternative embodiment of the present
invention employs a CPU field-programmable unit in place of the
mechanically set pin-and-jumper arrangement. In this example, input
control switches #1-#4 (max n=4) are provided to control any of
switching circuits #1-#16 (max m=16). Input lines from the input
control switches and output lines to the switching circuits are
connected to the pin terminals of the CPU, and the CPU is installed
with a program that allows setting of the input/output connections
in an electronic equivalent of the pin-and-jumper arrangement
(described below with reference to FIGS. 9-11). The CPU is coupled
to an LCD display and settings control knob (turn to scroll, push
to set) for setting the input/output connections in the field or
for onsite operation. As a further feature, the CPU may be
programmed to provide 7-day timer controls #1-#4 for automatic
on/off switching operation of the output circuits without the need
to manually activate external control signals.
[0032] In FIG. 7, a circuit board layout (without components) for
the CPU-controlled embodiment includes input terminals for control
switches #1-#4, 16 socket positions for plug-in PCBs for the Triac
switching circuits, and output terminals for output circuits
(switching poles) #1-#16. In FIG. 8, a typical installation wiring
scenario is shown in which 3 input control switches are installed,
and 10 output circuits are connected to respective light fixtures
and to circuit breakers on the ground (neutral) side.
[0033] FIGS. 9A-9G illustrate the programming of the CPU-controlled
input/output connections by an installer in the field or user for
onsite operation using the attached 4-line LCD display and setting
control knob. In FIG. 9A, a main menu display is shown prompting
the user to enter a passcode. Each digit of the passcode can be set
in sequence by turning the knob to bring the number up/down then
pushing the knob to set that digit. When all passcode digits have
been set, the knob is pushed to execute entry into the setting
program. In FIG. 9B, the main menu of the setting program prompts
the user to select which input control signal is to be set. The
control signal number can be set by turning the knob to bring the
number up/down then pushing the knob to set, then the knob is
pushed to execute. In FIG. 9C, the user is prompted to enter the
programming for connecting the selected control signal with the
desired output circuits ("active poles").
[0034] In FIG. 9D, the user is prompted to enter an active pole
number to be connected. The active pole number can be set by
turning the knob to bring the number up/down then pushing the knob
to set, then the knob is pushed to execute. In FIG. 9E, the user is
prompted to enter another pole number to be connected. In FIG. 9F,
the poles that have been set are displayed on the 3.sup.rd line of
the display. In FIG. 9G, the user can exit the setting program by
turning the knob until "Exit" appears in the pole number field,
then pushing the knob to exit.
[0035] The CPU is set to display the maximum number of input
control switches and active poles that the main PCB is designed
for. The control signal settings can be changed by the user at any
time. Not all switching poles need to be connected at the time of
initial onsite installation. Additional switching poles can be
added later and programmed to the desired control signal(s) onsite.
The setting program may be operated in a mode where only one
control signal can control a pole, so if the pole has been
previously assigned to another control signal, it will be removed
from the old control signal and be assigned to the currently
designed control signal. Alternatively, the program may operate in
a mode where more than one control signal can switch a pole, in
which case setting a current control signal would not erase a
previous setting for another control signal.
[0036] In FIG. 10, a control signal setup menu for the CPU is shown
which includes programming of 7-day calendar controls for automatic
on/off switching operation of the switching poles without the need
to manually activate external control signals. The menu allows the
user to step through the programming of each control signal by
assigning the switching poles (as described above), then setting
the 7-day calendar by stepping through the days of the week and
setting the hours/minutes time periods of on/off operation. In FIG.
11, a logic diagram for the programming the CPU is shown in which
the setting program steps through from the main menu and passcode
entry to setting any of the control signals #1-#4 by setting the
active poles to be connected to the control signal and the 7-day
time clock on/off periods.
[0037] Preferably, the main board contains all control signal
regulating circuits, input/output terminal blocks, and sockets for
the plug-in switching circuit boards. Power supply for switched
loads is obtained from any one of the switching circuits. Upon
failure of any circuit, the switching device can continue to
operate if there is power supplied to the other circuits. The first
switching circuit #1 is shown with a 4-position terminal block, as
2 positions are used for the control power neutral (ground
reference point). The device may be configured to accept outside
control power signals instead of onboard control power. The 7-day
calendars may be initialized to automatically adjust for daylight
savings and leap years. The output circuits can be grouped and
controlled by input control signals in any desired combination. The
modular design with plug-in components enabled additional units to
be installed at any time and programmed as desired.
[0038] It is understood that many modifications and variations may
b e devised given the above description of the principles of the
invention. It is intended that all such modifications and
variations be considered as within the spirit and scope of this
invention, as defined in the following claims.
* * * * *